3D Flitch Tracking for Saw Traceability in Lumber Processing
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Solution Overview
Problem
Lumber processing facilities face challenges in matching flitches to their source logs due to random stacking and incorrect picking, making it difficult to identify and address issues with saws that produce inconsistent flitch thickness, and they struggle to optimize cutting patterns for different tree species, leading to increased operational costs.
Innovation Solution
A system that uses geometric sensors and computer systems to generate 3D virtual models of logs and flitches, match actual flitches to predicted models, and adjust cutting equipment based on species-specific patterns, enabling precise identification of saw performance and optimal cutting strategies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flitches are stacked randomly on a queuing deck and picked up by an unscrambler, then the system can handle high volumes of flitches, but it becomes impossible to trace which saw cut which flitch, leading to inability to identify saw performance issues
Solution Approach 1:
The patent creates virtual 3D models (copies) of flitches that contain all the geometric and identification information. These digital twins track each flitch through the system, allowing traceability without physical tagging. The virtual model includes saw identification data, enabling tracking of which saw produced which flitch even after random stacking and unscrambling.
Solution Approach 2:
The patent introduces an intermediary tracking system that bridges the gap between physical flitch handling and digital record-keeping. Sensors capture flitch characteristics and create virtual models that serve as intermediaries, linking physical flitches to their source saws through digital identification without requiring physical tags or markers on the flitches themselves.
2Ease of operation
If generic cutting patterns are used for all logs, then the process is simple to operate, but cutting efficiency and profitability are reduced due to inability to optimize for different tree species
Solution Approach 1:
The patent applies local quality by tailoring cutting patterns to specific log characteristics. The system analyzes the virtual 3D model of each log and generates optimized cut patterns specific to that log's species, dimensions, and grain structure. This allows each log to receive customized cutting treatment rather than uniform generic patterns, maximizing yield from each specific log type.
Solution Approach 2:
The patent implements dynamic cutting patterns that adapt in real-time based on log characteristics. The system continuously adjusts cutting parameters based on the scanned geometry and species identification of each log, transforming the static generic cutting approach into a dynamic, log-specific optimization process that maximizes profitability.
3Device complexity
If traditional sensors are used to detect flitches, then the system is simple, but measurement precision is insufficient to accurately match flitches to source logs and identify saw issues
Solution Approach 1:
The patent merges multiple sensor types and measurement capabilities into an integrated sensing system. The system combines geometric scanning, species identification, and dimensional measurement capabilities into a unified virtual model creation process, achieving high measurement precision through the synergistic combination of multiple sensing functions rather than relying on a single simple sensor.
Data Source
AI summary
In various embodiments, a scanner optimizer system may generate a virtual model of a predicted flitch based on a 3D model of a log/cant and a cut solution for the log/cant. The scanner optimizer system may compare a virtual model of an actual flitch to virtual models of predicted flitches by comparing data points at a fixed elevation relative to one or both faces of the models. Based on the comparisons, the scanner optimizer system may identify the source log from which the actual flitch was cut. In addition, the scanner optimizer system may identify the saw used to cut the actual flitch, and/or other relevant information, and use the additional information to monitor and adjust the saws and other equipment. Embodiments of corresponding apparatuses and methods are also described.